Recovery of Rare Earth Elements (REEs) from Coal Mine …...2APP basin AMD discharge (Q) per Stewart...

Recovery of Rare Earth

Elements (REEs) from Coal

Mine Drainage

Paul Ziemkiewicz, Water Research Inst.

Xingbo Liu, Mechanical Engineering Dept.

West Virginia University

Aaron Noble, Mining Engineering Dept.

Virginia Tech

West Virginia Coal Association

Income Opportunities from Reclaimed

Mine Land

29 Jan 2018

Charleston WV

REE: RESOURCE

CHARACTERIZATION

• Demand

• Project Strategy

• Feedstock

– Acid mine drainage

– Treatment

– AMD precipitates

• Quality

• Quantity

Our strategic disadvantage:

China controls exports ~ 35kt/yr

Projected TREE demand through

2025 (tons/year)

This assumes that

USA manufacturing

demand does not

increase beyond

current rates

Global demand

@ 7% ann. Growth total* defense**

2017 158,403 15,840 792

2018 169,845 16,984 849

2019 182,176 18,218 911

2020 195,469 19,547 977

2021 209,804 20,980 1,049

2022 225,265 22,527 1,126

2023 241,947 24,195 1,210

2024 259,951 25,995 1,300

2025 279,387 27,939 1,397

* 10% global

** 5% USA demand

USA demand

?

?

USDOE Funded REE research at

WVU

Phase 1.

1. Development of a cost-effective & environmentally benign process to treat and recover REEs from AMD

2. Preliminary process system design and techno-economic analysis in preparation for pilot-scale testing

3. Down select by USDOE/NETL

Phase 2.

1. Build and operate a pilot plant

2. Report cost/performance

Participants

WVU

• Paul Ziemkiewicz, PhD– Director, WVU Water

Research Institute

• Xingbo Liu, PhD

– Professor, Mechanical and

Aerospace Engineering

• Aaron Noble, PhD

– Assistant Professor, Mining

Engineering

External

• Mepco Inc.

• Rosebud Mining Co.

• West Virginia Dept. of Environmental Protection

• Alliance Coal Corp.

• Consol Energy, Inc.

• Rockwell Automation

Objective: Develop new, sustainable market-driven

opportunities around domestic REE sources

Important criteria for attracting investment

• Size of the resource

• Market valuation

• Development costs – Preliminaries: exploration, planning, site development…

– capX

– opX

• Technology readiness (TRL)

• Environmental footprint– permitting

– liabilities

Mineral associations in WV coalsfrom WVGES

• Monazite (less commonly xenotime): REE (PO4 SiO4) weathered

from granite as micron-sized particles

• Does not dissolve in weak acid, requires concentrated acid to liberate

REEs

• When burned in a PC

boiler all of the inert

minerals fuse into

alumino-silicate glass

• Which is even more

Resistant to acid attack

Acid Mine Drainage: AMD1. H2SO4 leaches REEs from shale

2. REE’s precipitate with Fe(OH)3

Pyrite + O2 + H2O

= Fe2+ + H2SO4

Fe2+ + O2 + OH-

= Fe(OH)3

Pyrite

AMD sludge, Why We Care

• Inherent value: $225/kg of mixed Rare Earth oxide

• In-situ Rare Earth value of $96/t AMD sludge DW

• Refining cost = $65/t: estimated profit = $30/t

• 61% (dry weight) are the more valuable critical and heavy Rare

Earth Elements

• We estimate that a commercial refinery would recover its CapX

and OpX within 2.5 years

AMD Treatment

Precipitateseparation

Decant to regulateddischarge

Acid forms and leaches REE from coal waste rock

AMD moves along pit floor

Coal tailings or spoil

Acid neutralizationoxidation

Dewatering cells Deep mine

Typical AMD treatment and sludge handling

AMD sludge dewatering cell in Central WV

In-situ value = $1.3 million

AMD treatment

Acid mine drainage:

TREE Concentration vs. raw water pH

UG mine

Flooding status

controls REE

concentration

Flooded High Dilution

River

overburden

Mine

Discharge

Flooded Mine Low Dilution

River

overburden

Mine

Pump

No Discharge

Unflooded, Free Draining

River

overburden

Mine

Discharge

Low pH, hi REE

High pH, low REE

Heavy REEs are generally more valuable than light

H He

Li Be B C N O F Ne

Na Mg Al Si P S Cl Ar

K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr

Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe

Cs Ba La Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn

Fr Ra Ac

Ce Pr Nd Pm* Sm Eu Gd Tb Dy Ho Er Tm Yb Lu

Th Pa U Np Pt Am Cm Bk Cf Es Fm Md No Lr

Rare Earth ElementsLight Critical

Heavy *Unstable

Sampled locations: 140

CAPP

NAPP

CAPP VS. NAPP:

Little difference

between REE

distribution or total

concentration

(g/t)

Sites sampled:

CAPP 42

NAPP 110

CAPP NAPP All

La 41.4 38.4 39.9

Ce 97.1 95.0 96.0

Pr 14.4 14.0 14.2

Nd 66.5 64.5 65.5

Sm 18.2 17.6 17.9

Eu 4.4 4.5 4.4

Sc 12.8 14.9 13.8

Y 88.6 108.7 98.7

Gd 23.9 24.3 24.1

Tb 3.4 3.7 3.6

Dy 18.8 20.7 19.8

Ho 3.5 4.0 3.8

Er 9.1 10.7 9.9

Tm 1.0 1.4 1.2

Yb 6.7 8.1 7.4

Lu 0.9 1.2 1.0

TREE 410.6 431.6 421.1

Distribution of HREE in AMD sludge

is similar to south China clays

almost all

LREE

Bayan Obo, Mountain Pass South China Clay

50% HREE

- Sc

Heavy and Critical REEs n=155

% dry weight

REE concentrations and weighted in situ value

(n=155). LREE, HREE, Critical

Scandium represents 91% of weighted value.

LREE HREE

metal

value

In situ sludge value=market value of

REEs excluding transport and processing

Small AMD sludge drying cell0.5 ac, 10 ft deep, 80% moistureSludge DW 1,300 t$190/ton of sludge DW

In situ REE value = $247,000

Accessibility/extractability/dewatering

WVDEP-Omega AMD treatment site

14 Geotubes in cell: In-situ value $182,700

length 140 ft

width 20 ft

height 5 ft

volume 396 m3

moisture 65%

mass Dry Weight 146 t

REE mass 58 kg

in-situ value 225$ / kg

in-situ value 13,050$

One Geotube

Estimated REE production CAPP/NAPP

155 sites

Sampled

All Sites Units sites (n=140) est. total APP1 est. total APP2

Total Q L/sec 6,221 94,838 418,000

% total APP Q 6.56% 1.49%

Total TREE flux kg/year 41,395 631,059 2,781,412

In-situ value/year @ $225/kg TREE 9,313,905 141,988,220 625,817,729 1APP basin AMD discharge (Q) per this study2APP basin AMD discharge (Q) per Stewart et al., 2017

Sludge cells sampled to date: 155

Sludge 2,344,452 m3

solids content 21%

Sludge 519,413 tons DW

average TREE grade 419.1 g/t

TREE 217,686 kg

in-situ value 225.00$ /kg TREE

in-situ TREE value 48,979,379$

Next Step: Refine and separate

REEs to commercial grades

REE Recovery1. Acid Leaching

2. Solvent Extraction

3. Economics

Ore processed at its

acid heap leach and

solvent extraction plant

Gold mine near

Battle Mt., NV

Revenue potential: two scenarios(we are in the early stages of optimizing the

modular plant)

Parameter modular plant Centralized plant

6.25 t/hr 2100 t/daysludge feed grade

overall process recovery

weighted average metal quotation

inherent value

realization

REE concentrate production 1.36 t/day 29 t/day

internal rate of return 10% 46%

payback period (operating years) 18.5 years 2.5 yearsNet present value (1=10%) 47,217$ 63,454,000$

425 g/t, 65% moisture

87.20%

$225/kg REE

$96/t plant feed

$6100/t concentrate

Questions?

Paul Ziemkiewicz, PI

Director, WVU Water Research Institute

Morgantown WV

pziemkie@wvu.edu

304 293 6958